Method for manufacturing microprojection unit

Abstract

A method for manufacturing a microprojection unit ( 10 ) according to the invention involves: a microprojection tool forming step of forming a microprojection tool ( 1 ) by bringing a projecting mold part ( 11 ) into contact from one surface ( 2 D) side of a base sheet ( 2 A) including a thermoplastic resin, and thus forming a protrusion ( 3 ) that protrudes from another surface ( 2 U) side, and withdrawing the projecting mold part ( 11 ) from the interior of the protrusion ( 3 ); a joining step of joining the one surface ( 2 D) side of the base sheet ( 2 A), in which the microprojection tool ( 1 ) has been formed, and a tip end of a base component ( 4 ); and a cutting step of cutting the base sheet ( 2 A), to which the base component ( 4 ) has been joined, along a contour ( 4 L) of the base component ( 4 ) at a position more inward than the base component's contour ( 4 L) in a planar view of the base sheet ( 2 A) as viewed from the microprojection tool ( 1 ) side, to manufacture a microprojection unit ( 10 ).

The invention claimed is: 
     
       1. A method for manufacturing a microprojection unit that includes
 a microprojection tool, and 
 a base component, which is a member separate from the microprojection tool, the microprojection tool joined to a tip end of the base component, 
 the microprojection tool including a base and a protrusion provided so as to stand up on an upper surface of the base, 
 a base component having a liquid retention space in communication with the interior of the protrusion through the base, 
 the manufacturing method comprising: 
 a microprojection tool forming step including: 
 bringing a projecting mold part into contact from one surface side of a base sheet including a thermoplastic resin, and thus forming a protrusion that protrudes from another surface side of the base sheet, and 
 withdrawing the projecting mold part from the interior of the protrusion; 
 a joining step of joining: 
 the one surface side of the base sheet, in which the microprojection tool has been formed, and 
 the tip end of the base component; and 
 a cutting step of cutting the base sheet, to which the base component has been joined, along a contour of the base component at a position more inward than the base component's contour in a planar view of the base sheet as viewed from the microprojection tool side, to manufacture the microprojection unit; and 
 wherein the one surface side of the base sheet, in which the microprojection tool has been formed, and the tip end of the base component are joined together by forming a continuous joined region in the microprojection unit while causing the base component's tip-end wall portion and a portion of the base sheet located on the tip-end wall portion of the base component's peripheral wall portion to melt, and wherein a width of the continuous joined region in a planar view from the microprojection tool side is from 1 to 3 mm, or 
 wherein the one surface side of the base sheet, in which the microprojection tool has been formed, and the tip end of the base component are joined together by forming a continuous joined region in the microprojection unit while causing the base component's tip-end wall portion and a portion of the base sheet located on the tip-end wall portion of the base component's peripheral wall portion to melt, and wherein a spacing between the contour of the base of the microprojection tool and an outer-side peripheral edge of the continuous joined region is from 0.1 to 3 mm, or 
 wherein the one surface side of the base sheet, in which the microprojection tool has been formed, and the tip end of the base component are joined together by forming a continuous joined region in the microprojection unit while causing the base component's tip-end wall portion and a portion of the base sheet located on the tip-end wall portion of the base component's peripheral wall portion to melt, and wherein a spacing between an inner-side peripheral edge of the continuous joined region and an inner wall of a tip-end wall portion of a peripheral wall portion of the base component is from 0.1 to 3 mm. 
 
     
     
       2. The method for manufacturing a microprojection unit according to  claim 1 , wherein:
 the base component includes a peripheral wall portion around an outer periphery of the liquid retention space; and 
 in the cutting step, the base sheet is cut on a tip-end wall portion of the peripheral wall portion of the base component. 
 
     
     
       3. The method for manufacturing a microprojection unit according to  claim 1 , wherein the joining step includes joining with heat sealing, ultrasound, a laser, or an adhesive. 
     
     
       4. The method for manufacturing a microprojection unit according to  claim 1 , wherein the cutting step includes cutting with a punching blade or a laser. 
     
     
       5. The method for manufacturing a microprojection unit according to  claim 1 , wherein:
 in the joining step, a first lower opening plate is arranged on the one surface side of the base sheet and a first upper opening plate is arranged on the other surface side of the base sheet, and joining is performed in a state where the base sheet, in which the microprojection tool has been formed, is sandwiched between the first lower opening plate and the first upper opening plate; and 
 after the joining step, the first lower opening plate is moved downward and the first upper opening plate is moved upward. 
 
     
     
       6. The method for manufacturing a microprojection unit according to  claim 1 , wherein, in the joining step, a base component fixing part is arranged on the one surface side of the base sheet, and the base component is held in a manner that an outer shape of the base component's bottom portion side is fitted in a depression of the base component fixing part and the tip-end wall portion of the base component's peripheral wall portion is exposed. 
     
     
       7. The method for manufacturing a microprojection unit according to  claim 1 , wherein:
 in the joining step, a first lower opening plate is arranged on the one surface side of the base sheet, a first upper opening plate is arranged on the other surface side of the base sheet, and a joining member is arranged on the other surface side of the base sheet, and heating is performed at a tip-end portion of the joining member in a state where the base sheet, in which the microprojection tool has been formed, is sandwiched between the first lower opening plate and the first upper opening plate. 
 
     
     
       8. The method for manufacturing a microprojection unit according to  claim 7 , wherein a heating temperature when the joining member contacts the base sheet is from 100° C. to 300° C. 
     
     
       9. The method for manufacturing a microprojection unit according to  claim 7 , wherein a heating time when the joining member contacts the base sheet is from 0.1 to 5.0 seconds. 
     
     
       10. The method for manufacturing a microprojection unit according to  claim 7 , wherein, after the joining step, the joining member is moved upward, in a thickness direction, from the other surface side of the base sheet, the first lower opening plate is moved downward, and the first upper opening plate is moved upward. 
     
     
       11. The method for manufacturing a microprojection unit according to  claim 1 , wherein:
 in the cutting step, a second lower opening plate is arranged on the one surface side of the base sheet and a second upper opening plate is arranged on the other surface side of the base sheet, and the microprojection unit is manufactured in a state where the base sheet, to which the base component has been joined, is sandwiched between the second lower opening plate and the second upper opening plate; and 
 after the cutting step, the second lower opening plate is moved downward and the second upper opening plate is moved upward. 
 
     
     
       12. The method for manufacturing a microprojection unit according to  claim 1 , wherein:
 in the cutting step, a second lower opening plate is arranged on the one surface side of the base sheet, a second upper opening plate is arranged on the other surface side of the base sheet, and a cutting section is arranged on the other surface side of the base sheet, and the cutting section is passed through an opening of the second upper opening plate from the other surface side of the base sheet in a state where the base sheet, to which the base component has been joined, is sandwiched between the second lower opening plate and the second upper opening plate; and 
 the microprojection unit is manufactured by bringing a blade at a tip-end portion of the cutting section into contact with the other surface of the base sheet to cut the base sheet along the contour of the base component at a position more inward than the base component's contour in a planar view from the microprojection tool side. 
 
     
     
       13. The method for manufacturing a microprojection unit according to  claim 12 , wherein:
 after the cutting step, the cutting section is moved upward, in the thickness direction, from the other surface side of the base sheet, the second lower opening plate is moved downward, and the second upper opening plate is moved upward; and 
 then, a trimmed portion of the base sheet sandwiched between the second lower opening plate and the second upper opening plate is removed after moving the second lower opening plate downward and moving the second upper opening plate upward. 
 
     
     
       14. A method for manufacturing a microprojection unit that includes
 a microprojection tool, and 
 a base component, which is a member separate from the microprojection tool, the microprojection tool being joined to a tip end of the base component, 
 the microprojection tool including a base and a protrusion provided so as to stand up on an upper surface of the base, 
 a base component having a liquid retention space in communication with the interior of the protrusion through the base, 
 the manufacturing method comprising: 
 a microprojection tool forming step including 
 bringing a projecting mold part into contact from one surface side of a base sheet including a thermoplastic resin, and thus forming a protrusion that protrudes from another surface side of the base sheet, and 
 withdrawing the projecting mold part from the interior of the protrusion; and 
 a joining-cutting step of joining the one surface side of the base sheet, in which the microprojection tool has been formed, and the tip end of the base component, and simultaneously cutting the base sheet, along a contour of the base component at a position more inward than the base component's contour in a planar view of the base sheet as viewed from the microprojection tool side, to manufacture the microprojection unit; and 
 wherein the one surface side of the base sheet, in which the microprojection tool has been formed, and the tip end of the base component are joined together by forming a continuous joined region in the microprojection unit while causing the base component's tip-end wall portion and a portion of the base sheet located on the tip-end wall portion of the base component's peripheral wall portion to melt, and wherein a width of the continuous joined region in a planar view from the microprojection tool side is from 1 to 3 mm, or 
 wherein the one surface side of the base sheet, in which the microprojection tool has been formed, and the tip end of the base component are joined together by forming a continuous joined region in the microprojection unit while causing the base component's tip-end wall portion and a portion of the base sheet located on the tip-end wall portion of the base component's peripheral wall portion to melt, and wherein a spacing between the contour of the base of the microprojection tool and an outer-side peripheral edge of the continuous joined region is from 0.1 to 3 mm, or 
 wherein the one surface side of the base sheet, in which the microprojection tool has been formed, and the tip end of the base component are joined together by forming a continuous joined region in the microprojection unit while causing the base component's tip-end wall portion and a portion of the base sheet located on the tip-end wall portion of the base component's peripheral wall portion to melt, and wherein a spacing between an inner-side peripheral edge of the continuous joined region and an inner wall of a tip-end wall portion of a peripheral wall portion of the base component is from 0.1 to 3 mm. 
 
     
     
       15. The method for manufacturing a microprojection unit according to  claim 14 , wherein:
 in the joining-cutting step, a third lower opening plate is arranged on the one surface side of the base sheet and a third upper opening plate is arranged on the other surface side of the base sheet, and the microprojection unit is manufactured in a state where the base sheet, in which the protrusion has been formed, is sandwiched between the third lower opening plate and the third upper opening plate; and 
 after the joining-cutting step, the third lower opening plate is moved downward and the third upper opening plate is moved upward. 
 
     
     
       16. The method for manufacturing a microprojection unit according to  claim 1 , wherein a continuous base sheet is transported intermittently by: paying out the continuous base sheet from a material roll of the base sheet; transporting the base sheet in a transporting direction; and stopping transportation of the base sheet when the base sheet has been fed to a predetermined position. 
     
     
       17. The method for manufacturing a microprojection unit according to  claim 1 , wherein the method further comprises forming an opening in a vicinity of a tip of the protrusion by bringing the projection mold part into contact from one surface side a base sheet including a thermoplastic resin until it penetrates the base sheet. 
     
     
       18. The method for manufacturing a microprojection unit according to  claim 1 , wherein the base sheet and the base component each contain a thermoplastic resin and the joining of the one surface side of the base sheet, in which the microprojection tool has been formed, and
 the tip end of the base component comprises fusion-bonding. 
 
     
     
       19. The method for manufacturing a microprojection unit according to  claim 1 , wherein the method further comprises providing an ultrasonic vibration device which heats the projecting mold part. 
     
     
       20. The method for manufacturing a microprojection unit according to  claim 19 , wherein the ultrasonic vibration device heats the projection mold part to a temperature that is equal to or higher than the softening temperature of the base sheet and below the melting temperature of the base sheet.